Find the gap between OEE
and dependable throughput.

Crusoe Advisory uses MES data, OEE decomposition, and the Throughput Reliability Index to show where production reliability is breaking, what it costs, and which fix should happen first.

Start with one line    See the 10-day assessment

The Problem

Most plants know their OEE. Fewer know whether they can depend on their throughput.

Two lines can both average 62% OEE. One is stable, improving, and plannable. The other is volatile, shift-dependent, and quietly destroying schedule confidence. The average hides the difference.

Line OEE Reliability Momentum Interpretation First Move
Line A 62% Stable Improving Low but dependable Protect and standardize
Line B 62% Volatile Deteriorating Fragile throughput Immediate recovery sprint

OEE tells you the average. The Throughput Reliability Index tells you whether the average can be trusted.

The Framework

Throughput Reliability Index

TRI layers reliability measurement, variance decomposition, and economic translation on top of existing OEE data. It answers four questions:

Can you trust this line?

Can it hold performance across shifts, products, crews, and schedules — or is the average hiding swings?

Is it getting better or worse?

Is performance improving, stable, or quietly deteriorating in a way that won’t show up until it’s a crisis?

Where does the instability live?

Equipment, crew, product mix, materials, schedule, or process? Different root cause = different owner = different fix.

What is it costing you?

Overtime, missed orders, scrap, expediting, maintenance churn, safety stock — connected to dollars, not just percentages.

TRI does not replace Lean, TPM, digital twins, or OEE. It tells you where to apply them first.

How TRI Works →

Decision Layer

TRI is the decision layer between your data and your operating system.

  • OEE measures loss.
  • Lean defines waste and improvement routines.
  • TPM protects asset reliability.
  • Digital twins model expected performance.
  • MES records what happened.
  • TRI ranks where throughput reliability is breaking and what action should happen first.
$1.7M+ Documented savings across six facilities
$1.4M Hidden exposure surfaced in a single 4-line assessment
38% Changeover reduction using MES data & SMED
92.6% Of major downtime events preceded by short-stop clusters
8+ Years on food & CPG production floors
15+ hrs/wk Manual reporting eliminated per facility

Built by a Lean Six Sigma Black Belt with 8+ years on food and CPG production floors.

Start with one line. Ten business days. One decision-ready report.

Send us 90 days of shift-level OEE data. We’ll run the assessment and show you the operating reality beneath the averages.

Book a 30-Minute Fit Call    See the Case Study →